Thin-walled elastic products and methods and systems for manufacturing same

Abstract

One method for creating barrier products (for example, condoms and gloves) includes: (a) dipping a former into a tank of elastic compound. The former has an indentation extending inwardly from an outer surface for creating a first protrusion on a first face of the barrier product. The method further includes: (b) removing the former from the tank of elastic compound, whereby some of the elastic compound removably adheres to the former and fills the indentation; (c) applying supplemental material to the elastic compound, whereby creating a second protrusion on a second face of the barrier product; and (d) fully drying the supplemental material. One barrier product includes an elastic wall having opposed faces, and first and second protrusions respectively extend from the opposed faces. The first and second protrusions are in cross-sectional alignment whereby rotational input forces on the first protrusion create rotational output forces on the second protrusion.

The invention claimed is: 
     
       1. A method for creating a barrier product, the method comprising the steps:
 (a) dipping a former into a tank of elastic compound, the former having an outer surface and an indentation, the indentation extending inwardly from the outer surface for creating a first protrusion on a first face of the barrier product; 
 (b) removing the former from the tank of elastic compound, whereby some of the elastic compound removably adheres to the former, a portion of the removably adhered elastic compound filling the indentation; 
 (c) at least one of:
 (1) mapping the indentation into computer memory; and 
 (2) sensing the indentation; 
 
 (d) applying supplemental material to the elastic compound removably adhered to the former, whereby creating a second protrusion on a second face of the barrier product; and 
 (e) fully drying the supplemental material; 
 wherein applying supplemental material in step (d) comprises applying as least part of the supplemental material as a cylinder, the cylinder having an axis generally perpendicular to the second face; and 
 wherein applying supplemental material in step (d) comprises at least one of:
 (1) controlling an applicator to apply the supplemental material in cross-sectional alignment with the former indentation using the mapping in the computer memory, whereby the first protrusion is aligned with the second protrusion; and 
 (2) controlling an applicator to apply the supplemental material in cross-sectional alignment with the former indentation using the sensing, whereby the first protrusion is aligned with the second protrusion. 
 
 
     
     
       2. The method of  claim 1 , further comprising the steps:
 (i) partially drying the removably adhered elastic compound; and 
 (ii) fully drying the removably adhered elastic compound; 
 wherein step (i) occurs before step (d), and wherein step (ii) occurs after step (d). 
 
     
     
       3. The method of  claim 1 , further comprising the steps:
 (i) partially drying the removably adhered elastic compound; and 
 (ii) fully drying the removably adhered elastic compound; 
 wherein step (i) occurs before step (d), and wherein step (ii) occurs before step (d). 
 
     
     
       4. The method of  claim 1 , further comprising the step:
 (i) partially drying the supplemental material; 
 wherein step (i) occurs before step (d). 
 
     
     
       5. The method of  claim 1 , wherein applying supplemental material in step (d) comprises projecting the supplemental material onto the removably adhered elastic compound with an applicator such that the applicator does not touch the removably adhered elastic compound. 
     
     
       6. The method of  claim 5 , further comprising the step:
 (i) partially drying the supplemental material; 
 wherein step (i) occurs before step (d). 
 
     
     
       7. The method of  claim 1 , wherein at least part of the indentation has a cylindrical configuration. 
     
     
       8. The method of  claim 1 , wherein the elastic compound includes at least one item selected from the group consisting of latex, polyurethane, polyisoprene, nitrile rubber, polyvinyl chloride, silicone, and neoprene. 
     
     
       9. The method of  claim 8 , wherein the composition of the supplemental material is the same as the composition of the elastic compound. 
     
     
       10. The method of  claim 9 , further comprising the steps:
 (i) partially drying the removably adhered elastic compound; and 
 (ii) fully drying the removably adhered elastic compound; 
 wherein step (i) occurs before step (d), and wherein step (ii) occurs after step (d). 
 
     
     
       11. The method of  claim 10 , further comprising the step:
 (iii) partially drying the supplemental material; 
 wherein step (iii) occurs before step (d). 
 
     
     
       12. The method of  claim 9 , further comprising the steps:
 (i) partially drying the removably adhered elastic compound; and 
 (ii) fully drying the removably adhered elastic compound; 
 wherein step (i) occurs before step (d), and wherein step (ii) occurs before step (d). 
 
     
     
       13. The method of  claim 12 , further comprising the step:
 (iii) partially drying the supplemental material; 
 wherein step (iii) occurs before step (d). 
 
     
     
       14. The method of  claim 1 , wherein the barrier product is a condom. 
     
     
       15. A method for creating a barrier product, the method comprising the steps:
 (a) dipping a former into a tank of elastic compound, the former having an outer surface and an indentation, the indentation extending inwardly from the outer surface for creating a first protrusion on a first face of the barrier product; 
 (b) removing the former from the tank of elastic compound, whereby some of the elastic compound removably adheres to the former, a portion of the removably adhered elastic compound filling the indentation; 
 (c) at least one of:
 (1) mapping the indentation into computer memory; and 
 (2) sensing the indentation; 
 
 (d) producing a second protrusion on a second face of the barrier product, the second protrusion being in cross-sectional alignment with the first protrusion; and 
 (e) fully drying the elastic compound; 
 wherein step (a) is performed before step (b), step (b) is performed before step (d), and step (d) is performed before step (e); and 
 wherein the elastic compound includes ferromagnetic particles, and wherein producing a second protrusion in step (d) comprises electromagnetically drawing some of the removably adhered elastic compound away from the former using at least one of:
 (1) the mapping in the computer memory; and 
 (2) the sensing. 
 
 
     
     
       16. The method of  claim 15 , wherein the barrier product is a condom.